U.S. patent application number 13/426800 was filed with the patent office on 2012-07-12 for elastomeric ball and method of manufacturing same.
This patent application is currently assigned to Hasbro, Inc.. Invention is credited to Robert L. Brown, So Ho Fai, Kenneth Lau, Lee Yiu Wah.
Application Number | 20120177777 13/426800 |
Document ID | / |
Family ID | 45990787 |
Filed Date | 2012-07-12 |
United States Patent
Application |
20120177777 |
Kind Code |
A1 |
Brown; Robert L. ; et
al. |
July 12, 2012 |
Elastomeric Ball and Method of Manufacturing Same
Abstract
The present invention is directed to a ball including an outer
shell formed from a first thermoplastic material and having an
inner surface defining a cavity, outer details formed from a second
thermoplastic material and disposed on at least a portion of the
outer surface of the outer shell, and a core formed from a foamable
polymeric material and disposed within the cavity of the outer
shell. The ball may be produced by forming a pair of half shells
having inner surfaces defining corresponding portions of the cavity
of the outer shell, forming the outer details on the outer surface
of at least one of the half shells, and foaming a polymeric
material to form the core.
Inventors: |
Brown; Robert L.; (North
Kingstown, RI) ; Fai; So Ho; (Kowloom, HK) ;
Wah; Lee Yiu; (ApLeiChau, HK) ; Lau; Kenneth;
(Tai Wai, HK) |
Assignee: |
Hasbro, Inc.
Pawtucket
RI
|
Family ID: |
45990787 |
Appl. No.: |
13/426800 |
Filed: |
March 22, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11957106 |
Dec 14, 2007 |
8168026 |
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13426800 |
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11197020 |
Aug 4, 2005 |
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11957106 |
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Current U.S.
Class: |
425/588 |
Current CPC
Class: |
B29C 33/26 20130101;
B29C 44/129 20130101; A63B 37/06 20130101; A63B 2243/007 20130101;
A63B 37/12 20130101; B29C 45/1615 20130101; B29C 44/1233 20130101;
A63B 45/00 20130101 |
Class at
Publication: |
425/588 |
International
Class: |
B29C 45/03 20060101
B29C045/03 |
Claims
1-26. (canceled)
27. An apparatus for forming a ball having an outer shell
comprising a pair of half shells formed from a first thermoplastic
material, outer details formed from a second thermoplastic material
and molded onto at least a portion of the outer surface of the
outer shell, and a core formed from a foamable polymeric material
and disposed within a cavity defined by an inner surface of the
outer shell, the apparatus comprising: a first injection mold
having a molding cavity corresponding to the shape of a half shell
of the outer shell; a second injection mold having a molding cavity
configured to receive a half shell and engage the inner surface of
the half shell, to engage the portions of the outer surface of the
half shell that will not have outer details molded thereon, and to
form at least one detail moding cavity corresponding to the shape
of an outer detail and defined by a portion of the outer surface of
the half shell on which the outer detail will be molded and a
corresponding surface of the second injection mold; and a foam mold
having a molding cavity corresponding to the shape of the ball and
configured to receive two half shells having outer details molded
thereon.
28. An apparatus for forming a ball as defined in claim 27, wherein
the first injection mold comprises a first mold element and a
second mold element having surfaces that, when the first and second
mold elements are in a closed position, define the molding cavity
corresponding to the shape of the half shell, wherein the surface
of the first mold element defines the inner surface of the half
shell and the surface of the second mold element defines the outer
surface of the half shell, and the second injection mold comprises
the first mold element of the first injection mold and a third mold
element having a surface that, when the first and third mold
elements are in a closed position with the half shell disposed
therein, the at least one detail molding cavity is defined by the
portion of the outer surface of the half shell on which the outer
detail will be molded and a corresponding surface of the third mold
element.
29. An apparatus for forming a ball as defined in claim 27,
comprising a spray nozzle in fluid communication with a pressurized
source of an adhesive, the nozzle applying adhesive to the inner
surfaces of the half shells when the half shells are disposed in
the foam mold and the foam mold is in an open position.
30. An apparatus for forming a ball as defined in claim 27, wherein
the molding cavity of the second injection mold is configured to
mold outer details on a portion of the outer surface of the half
shell and not on the entire outer surface of the half shell.
Description
BACKGROUND
[0001] The patent is directed to a ball, and more particularly to a
ball and a method of manufacturing a ball having polyurethane (PU)
core, a polyvinyl chloride (PVC) shell, and PVC detailing covering
at least a portion of the outer surface of the PVC shell.
[0002] Various balls fabricated from multiple layers of material
and manufactured by molding processes have been previously
described. For example, U.S. Pat. No. 3,932,107 to Proudfit
discloses an apparatus for forming a composite article including an
inflatable center adapted to retain a predetermined shape covered
with a covering of molded material and preferably an inflatable
composite article such as a game ball with a covering of more
uniform thickness. Surfaces of complementary elements of a mold are
adapted to define, when the mold is closed, a molding cavity
corresponding to the outer surface of a desired composite article.
The surfaces are electrostatically sprayed with a molding material
to form a layer of molding material over the surfaces. An
inflatable center is then inserted into the mold and the mold is
closed to define the molding cavity with the inflatable center
therein. Thereafter, the inflatable center is inflated to compress
the molding material against the surfaces of the molding cavity to
produce mold details. The mold is then heated to fuse the molding
material to the desired covering for the inflatable composite
article. Subsequently, the mold is cooled and the composite article
is removed from the mold.
[0003] U.S. Pat. No. 4,462,589 to Morgan discloses a durable,
composite safety ball formed with a soft, resilient, substantially
closed-cell plastic foam core. The safety ball, including the
cover, has a type A durometer less than about 60 and preferably in
the range of about 25 to about 45. Preferably the core is
surrounded by an inner skin which is formed to substantially
prevent the entry of water into the foam of the core and, together
with an outer heavy, tightly knit nylon cover, to provide
sufficient strength to hold the soft cellular plastic foam together
as a unit. The soft foam core is preferably a urethane foam and
enables the formation of balls which have a performance similar to
regulation baseballs and softballs and yet will not produce a
substantial risk of injury to players or risk of property damage.
The composite safety ball is also sting-free and has a long useful
life.
[0004] U.S. Pat. No. 4,463,951 to Kumasaka et al. discloses a ball
for a game having a spherical soft polyurethane foam and a surface
layer of foamed polyvinyl chloride formed on the surface of the
spherical body. The ball is produced by first casting the surface
layer in a mold to form a hollow foamed PVC body having closed
cells, and then charging a foamed polyurethane composition into the
hollow thus formed, to produce a sphere of polyurethane having open
cells within the surface layer. Also provided is a ball for games
having a spherical body of foamed polyvinyl chloride and having a
spherical cavity at the center. The ball is safe, has proper
flexibility, and is not subject to punctures.
[0005] U.S. Pat. No. 5,427,372 to Ratner et al. discloses a play
ball having visually distinctive colored patches distributed over
its exterior. Portions of the ball exterior may be uncovered with
patches, and have a color distinct from the color of the patches.
Regions of different tactile patterns are impressed on the ball,
and these regions may match all or parts of differently colored
patches. Ratner et al. also discloses a method of making a game
ball with patches on its exterior.
[0006] U.S. Pat. No. 5,984,812 to Sassak discloses a mesh panel for
throwable and/or grippable objects such as footballs, baseballs,
basketballs, baseball bats, etc. The mesh panel is formed from
polyvinyl chloride and includes a plurality of openings surrounded
by a plurality of connecting portions. The outer surface of the
mesh panel is such that each of the connecting portions includes a
plurality of rib portions which further enhance the ability to grip
the mesh panel. The inside surface of the mesh panel has an
adhesive coating which bonds to an outer surface of the object to
which the mesh panel is attached when heat is applied to the mesh
panel. The heating of the mesh panel also causes a sticky,
resin-like outer surface to be formed. The mesh panel enables
various objects such as footballs, baseballs, basketballs, baseball
bats, etc. to be much more easily grasped, thrown and caught by
individuals of all ages and sizes, and particularly by individuals
such as small adults and children having relatively small hands.
The mesh panel is durable, does not add appreciable weight to the
object to which it is attached or otherwise significantly affect
the aerodynamics or trajectory of throwable objects to which the
mesh panel is attached.
[0007] U.S. Pat. No. 6,685,584 to Jin et al. discloses a game ball
having improved gripability. The game ball includes a bladder and a
cover. The cover is positioned over the bladder. The cover has an
inner surface and an outer surface. The cover has a first
impression pattern formed into, and covering at least a portion of,
the outer surface. The first impression pattern forms a plurality
of outwardly extending raised surfaces on the outer surface. The
cover further has a second impression pattern formed into the
raised surfaces of the outer surface. The second impression pattern
is configured to improve the gripability of the game ball.
SUMMARY OF THE INVENTION
[0008] In one aspect, the invention is directed to a ball having an
outer shell formed from a first thermoplastic material and having
an inner surface defining a cavity, outer details formed from a
second thermoplastic material and disposed on at least a portion of
the outer surface of the outer shell, and a core formed from a
foamed polymeric material and disposed within the cavity of the
outer shell.
[0009] In another aspect, the present invention is directed to a
method of manufacturing a ball that may include forming a pair of
half shells of an outer shell by molding a first thermoplastic
material, wherein the inner surfaces of the half shells define
corresponding portions of a cavity within the outer shell, and
forming outer details on at least a portion of the outer surface of
at least one of the half shells by molding a second thermoplastic
material onto the outer surface of the at least one of the outer
shells. The method may also include foaming a polymeric material
within the cavity of the outer shell to form a core of foamed
polymeric material within the cavity of the outer shell.
[0010] In a further aspect, the invention is directed to a ball
including an outer shell formed from a first thermoplastic material
and having an inner surface defining a cavity, outer details formed
from a second thermoplastic material and disposed on at least a
portion of the outer surface of the outer shell, and a core formed
from a foamable polymeric material and disposed within the cavity
of the outer shell. The ball may be produced by forming a pair of
half shells having inner surfaces defining corresponding portions
of the cavity of the outer shell, forming the outer details on the
outer surface of at least one of the half shells, and foaming a
quantity of the polymeric material in the cavity to form the
core.
[0011] In a still further aspect, the invention is directed to an
apparatus for forming a ball that may have an outer shell
comprising a pair of half shells formed from a first thermoplastic
material, outer details formed from a second thermoplastic material
and molded onto at least a portion of the outer surface of the
outer shell, and a core formed from a foamable polymeric material
and disposed within a cavity defined by an inner surface of the
outer shell. The apparatus may include a first injection mold
having a molding cavity corresponding to the shape of a half shell
of the outer shell, and a second injection mold having a molding
cavity configured to receive a half shell and engage the inner
surface of the half shell. The molding cavity of the second
injection mold may further be configured to engage the portions of
the outer surface of the half shell that will not have outer
details molded thereon, and to form at least one detail molding
cavity corresponding to the shape of an outer detail and defined by
a portion of the outer surface of the half shell on which the outer
detail will be molded and a corresponding surface of the second
injection mold. The apparatus may further include a foam mold
having a molding cavity corresponding to the shape of the ball and
configured to receive two half shells having outer details molded
thereon.
[0012] Additional aspects of the invention are defined by the
claims of this patent.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of an embodiment of a ball in
accordance with the invention;
[0014] FIG. 2 is a partially cutaway view of the ball of FIG.
1;
[0015] FIG. 3 is a cross-sectional view of the ball of FIG. 1 taken
along line 3-3,
[0016] FIG. 4 is a flow chart of a process for fabricating the ball
of FIG. 1 in accordance with the invention;
[0017] FIG. 5 is a cross-sectional view of an injection mold for
injection molding a half shell of the ball of FIG. 1 during the
process of FIG. 4;
[0018] FIG. 6 is a cross-sectional view of an injection mold for
injection molding details onto the outer surface of a half shell of
the ball of FIG. 1 during the process of FIG. 4; and
[0019] FIG. 7 is a cross-sectional view of a foam mold for molding
the inner core within the shell of the ball of FIG. 1 during the
process of FIG. 4 in an open position.
DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS
[0020] Although the following text sets forth a detailed
description of numerous different embodiments of the invention, it
should be understood that the legal scope of the invention is
defined by the words of the claims set forth at the end of this
patent. The detailed description is to be construed as exemplary
only and does not describe every possible embodiment of the
invention since describing every possible embodiment would be
impractical, if not impossible. Numerous alternative embodiments
could be implemented, using either current technology or technology
developed after the filing date of this patent, which would still
fall within the scope of the claims defining the invention.
[0021] It should also be understood that, unless a term is
expressly defined in this patent using the sentence "As used
herein, the term `______` is hereby defined to mean . . . " or a
similar sentence, there is no intent to limit the meaning of that
term, either expressly or by implication, beyond its plain or
ordinary meaning, and such term should not be interpreted to be
limited in scope based on any statement made in any section of this
patent (other than the language of the claims). To the extent that
any term recited in the claims at the end of this patent is
referred to in this patent in a manner consistent with a single
meaning, that is done for sake of clarity only so as to not confuse
the reader, and it is not intended that such claim term by limited,
by implication or otherwise, to that single meaning. Finally,
unless a claim element is defined by reciting the word "means" and
a function without the recital of any structure, it is not intended
that the scope of any claim element be interpreted based on the
application of 35 U.S.C. .sctn. 112, sixth paragraph.
[0022] Referring to FIG. 1, a ball 10 in accordance with the
present invention may include an outer shell 12 formed from a first
thermoplastic material, and details 14, 16 formed from a second
thermoplastic material overmolded onto at least a portion of the
outer surface of the shell 12. In the illustrated embodiment, the
ball 10 is shaped to resemble a football, with the over molded
details 14 simulating the seams, laces and lines of a football and
providing enhanced gripping surfaces for the user. The overmolded
detailed 16 may provide additional details on the outer surface of
the shell 12, such as lettering, logos and the like, and may also
provide additional gripping surfaces for the user.
[0023] Turning to FIG. 2, portions of the shell 12 and details 14,
16 are cut away to reveal an inner core 18 that may be fabricated
from a foamed polymeric material, such as a polyurethane foam, and
that may fill the cavity defined by the inner surface of the shell
12. The core 18 may fill the entire cavity within the shell 12 and
engage the inner surface of the shell 12 as shown in FIG. 3. As
further described below, half shells 22, 24 of the shell 12 may be
formed separately and, later in the process, adhered or otherwise
connected together to form the shell 12 when the inner core 18 is
formed therein. As a result, a seam 20 may exist at the interface
between the half shells 22, 24. In addition, the shell 12 and, if
necessary, the details 14 may have a venting hole 26 formed
therethrough (FIGS. 1 and 2). The venting hole 26 may be configured
to vent gas from the interior of the shell 12 when the core 18 is
formed by foaming the polymeric material, and may be located in an
appropriate position on the ball 10, such as at one tip of the
football, to vent the gas as discussed in the process described
below.
[0024] The shell 12, details 14, 16, and the core 18 may be molded
during the process described below, and may be fabricated from any
thermoplastic and foamed polymeric materials necessary to yield the
desired performance characteristics for the ball 10. For example,
in a football such as the football 10 in the illustrated
embodiment, it may be desired that the final product have a
hardness in the range of 55 to 72 degrees on a shore 00 durometer
scale as measured at the portions of the outer surface of the shell
12 that are not covered by the outer details 14, 16, and a hardness
in the range of 67 to 82 degrees on a shore 00 durometer scale as
measured at the outer details 14, 16. In one embodiment, these
hardness ranges for the football 10 may be achieved where the first
thermoplastic material forming the shell 12 may be a PVC compound
having a hardness of approximately 50 degrees on a shore A
durometer scale, the second thermoplastic material forming the
outer details 14, 16 may be a PVC compound having a hardness of
approximately 20 degrees on a shore A durometer scale, and the
foamed polymeric material forming the core 18 may be a high
resilience polyurethane foam composed of polyal (approximately
53%), isocyanate (approximately 37%), blowing agent (approximately
7%) and other additives and fungi preventol (approximately 3%).
Further, while the first and second thermoplastic materials may he
similar compounds, at least in their hardness properties, the
materials may have different colors to achieve a desired appearance
for the ball 10. Those skilled in the art will understand that the
ball 10 may be fabricated from other combinations of materials to
produce a ball 10 having the desired performance characteristics,
and they will be able to select such materials and utilize the
methods described herein to manufacture the hall 10 having the
desired performance characteristics. Moreover, while the
illustrated embodiment shows the shell 12 being formed by two half
shells 22, 24 that are symmetrical with respect to each other, and
which each form half of the shell 12, the half shells 22, 24 may be
asymmetrical if desired, and each form different proportions of the
shell 12 and still combine to form the shape of the ball 10. Still
further, depending on the implementation, the shell 12 may be
formed from three or more shell portions if desired.
[0025] FIG. 4 is a flowchart of an embodiment of a process 100 in
accordance with the invention for fabricating the ball 10. The
process 100 may begin at a step 102 wherein the half shells 22, 24
may be injection molded from the first thermoplastic material. FIG.
5 illustrates one example of a half shell injection mold 30 that
may be used in fabricating the half shells 22, 24. The injection
mold 30 may include an inner surface mold element 32 and an outer
surface mold element 34 defining a cavity 36 in the shape of a half
shell 22, 24. While not shown, the mold elements 32, 34 may also be
shaped to form the venting hole 36 of the shell 12. The inner
surface mold element 32 may include a rib 38, and the outer surface
mold element 34 may include a corresponding channel 40 mating with
the rib 38 to ensure that the mold elements 32, 34 are properly
aligned for forming the half shell 22, 24. The outer surface mold
element 34 may further include an inlet 42 placing the cavity 36 in
fluid communication with the exterior of the outer surface mold
element 34 such that a source of the first thermoplastic material
may be connected thereto to supply the first thermoplastic material
through the inlet 42 and into the cavity 36 to form the half shell
22, 24 in a conventional injection molding process. The first
thermoplastic material is injected through the inlet 42, and the
injection molding process occurs at the appropriate temperature and
pressure for the selected first thermoplastic polymer.
[0026] Returning to FIG. 4, after the half shell 22, 24 is
injection molded at step 102, the details 14, 16 may be overmolded
onto the outer surface of the half shell 22, 24 at a step 104. FIG.
6 illustrates a detail injection mold 50 in which the outer surface
mold element 34 of the half shell injection mold 30 is removed and
replaced with a detail outer surface mold element 52 that connects
to the inner surface mold element 32 with a channel 54 mating with
the rib 38 to align the mold elements 32, 52. In the illustrated
embodiment, the previously-molded half shell 22, 24 may be retained
on the inner surface mold clement 32 when the outer surface mold
element 34 is removed and the detail outer surface mold element 52
is substituted therefore. The inner surface of the detail outer
surface mold element 52 may he configured generally to conform to
and engage the outer surface of the half shell 22, 24, and to
include portions forming cavities 56, 58 corresponding to the
details 14, 16 to be overmolded onto the outer surface of the half
shell 22, 24. The cavity 56 corresponds to the details 14 as seen
in FIGS. 1 and 2, and the cavity 58 corresponds to the details 16
that are formed separately and detached from the details 14. As a
result, the detail outer surface mold element 52 may include an
inlet 60 therethrough placing the cavity 56 in fluid communication
with the exterior of the mold element 52, and having a separate
channel 62 extending between the inlet 60 and the cavity 58 to
cause a portion of the second thermoplastic material provided by a
pressurized source to the detail injection mold 50 to be diverted
through the channel 62 and into the cavity 58 to form the details
16 at the desired location on the outer surface of the half shell
22, 24.
[0027] Those skilled in the art will understand that the
overmolding of the detail onto the outer surface of the half shell
22, 24 may be performed at the typical temperatures and pressures
necessary to perform injection molding of the selected
thermoplastic material. Depending on the particular characteristics
of the first and second thermoplastic materials selected for the
ball 10, the details 14, 16 may be overmolded directly onto the
outer surface of the half shell 22, 24, with the second
thermoplastic material interacting with the first thermoplastic
material to form the necessary bond for attachment of the details
14, 16 to the outer surface of the half shell 22, 24.
Alternatively, if necessary, an appropriate adhesive may be applied
to the outer surface of the half shell 22, 24 prior to assembly of
the detail injection mold 50 such that the overmolded details 14,
16 adhere to the outer surface of the half shell 22, 24 with
sufficient strength to satisfy the requirements for the particular
ball 10 being fabricated.
[0028] Once the details 14, 16 are overmolded onto the outer
surface of the half shells 22, 24, the process 100 of FIG. 4 may
proceed to a step 106 wherein the half shells 22, 24 may be removed
from the injection mold 50 and mounted within a foam mold, such as
the foam mold 70 shown in FIG. 7. The foam mold 70 may include a
first foam mold element 72 receiving a half shell 22, and a second
foam mold element 74 receiving a half shell 24. The inner surfaces
of the mold elements 72, 74 may be shaped to correspond to the
shape of the outer surfaces of the half shells 22, 24,
respectively, and of the details 14, 16 overmolded thereon.
Configured in this way, the mold elements 72, 74 may support the
half shells 22, 24 during the foaming of the polymeric material
that will form the core 18 of the ball 10. In one embodiment, the
foam mold 70 may include a hinge 76 pivotally connecting the foam
mold elements 72, 74 such that one of the mold elements 72, 74 may
be rotated with respect to the other mold elements 72, 74 to close
the mold during the foam molding process. In order to ensure proper
alignment, the foam mold element 72 may include a raised rib 64 and
the second foam mold element 74 may include a corresponding channel
66 that may mate with the rib 64 when the foam mold 70 is closed to
properly align the inner surfaces of the mold elements 72, 74 and
half shells 22, 24. In order to allow gas to escape from the
interior of the ball 10 through the venting hole 26 as the foaming
polymeric material expands during the foam molding process, the
first foam mold element 72 may include an air passage 82 that may
place the venting hole 26 and, correspondingly, the interior of the
ball 10 in fluid communication with the ambient atmosphere to allow
the gas to be released when the foam mold 70 is closed. If
necessary, the second foam mold element 74 may have a recess 84
corresponding to the air passage 82 such that the air passage 82 is
not constricted when the foam mold 70 is closed.
[0029] After mounting the half shells 22, 24 in the foam mold 70 at
step 106, the process 100 of FIG. 4 may proceed to a step 108
wherein an adhesive may be applied to the rims and the inner
surfaces of the half shells 22, 24 at a step 108. The adhesive may
be applied to the half shells 22, 24 manually, or a spray nozzle
may be used to apply adhesive supplied by a pressurized source of
the adhesive. In one embodiment, the adhesive may be a general
polyurethane adhesive composed of toluene (20-30%), methyl ethyl
ketone (30-40%), acetone (25-30%) and polyurethane (13.5-15.5%).
Those skilled in the art will understand that the need for an
adhesive and the properties of the adhesive may be dictated by the
requirements for the ball 10 being fabricated and the thermoplastic
materials and foamed polymeric materials being used to fabricate
the ball 10. For example, to achieve desired performance
characteristics for the ball 10, it may not be necessary to have
the core 18 adhere to the inner surface of the shell 12. Further,
the properties of the thermoplastic material used to form the shell
12 and the foam polymeric material used to form the core 18 may be
selected such that the materials adhere during the foaming of the
foaming polymeric material. For example, the first thermoplastic
material may be a PVC compound and the polymeric material may be a
polyurethane compound with a vinyl add mixture such that the vinyl
in the polyurethane compound may bond with the PVC compound of the
shell 12 to secure the core 18 to the inner surface of the shell
12.
[0030] After the adhesive is applied to the half shells 22, 24 at
step 108, if necessary, the process 100 of FIG. 4 may continue with
a step 110 wherein the polymeric material may be poured into one of
the half shells 24 at a step 110, and the foam mold 70 may be
closed and the polymeric material may be foamed at a step 112.
Returning to FIG. 7, the polymeric material 86 in a liquefied form
may be poured into one of the foam mold elements, such as a second
foam mold element 74 as illustrated, and the first foam mold
element 72 may be rotated about hinge 76 to close the foam mold 70.
Once the foam mold 70 is closed, the foam mold 70 may be rotated to
a vertical position with the air passage 82 disposed at the top of
the foam mold 70 so that gas may be released through the venting
hole 26 and the air passage 82 as the foamed polymeric material 86
expands within the shell 12. As with the other molding steps in the
process 100, the foam mold 70 may be heated to the temperature
necessary to cause the particular polymeric material 86 chosen for
the core 18 to foam and expand within the shell 12. Once the foamed
polymeric material 86 expands to fill the shell 12 and form the
core 18, the foam mold 70 may be opened and the fully fabricated
ball 10 may be removed from the foam mold 70 at a step 114.
[0031] Those skilled in the art will understand that the method
illustrated in FIG. 4 may be modified as necessary to fabricate
ball 10 in accordance with the present invention. For example,
while the process 100 includes pouring the polymeric material 86
into at least one of the half shells 22, 24 at step 110 and then
closing the foam mold 70 and forming the core 18 at step 112, the
process 100 may be modified such that the foam mold 70 may be
closed first, and then the polymeric material 86 may be poured or
injected into the cavity of the shell 12 prior to foaming the
polymeric material 86. In such a modified process, it may be
necessary to configure the molds 30, 50 and 70 to form a venting
hole 26 and provide an air passage 82 having sufficient size, or to
provide larger material inlet holes in the shell 12 and mold 70, to
facilitate pouring or injecting the polymeric material 86 into the
cavity after the mold 70 is closed. Depending on the size of the
venting hole 26 or inlet hole through the shell 12, it may further
be necessary to provide a plug fabricated from an appropriate
material to close the venting hole 26 or inlet hole for cosmetic
purposes after the core 18 is formed. Other modifications to the
process 100 may be apparent to those skilled in the art and are
contemplated by the inventors as having use with the method and the
ball in accordance with the present invention.
[0032] While the preceding text sets forth a detailed description
of numerous different embodiments of the invention, it should be
understood that the legal scope of the invention is defined by the
words of the claims set forth at the end of this patent. The
detailed description is to be construed as exemplary only and does
not describe every possible embodiment of the invention since
describing every possible embodiment would be impractical, if not
impossible. Numerous alternative embodiments could be implemented,
using either current technology or technology developed after the
filing date of this patent, which would still fall within the scope
of the claims defining the invention.
* * * * *